Insulation cover for attic closures

ABSTRACT

Covers for attic trap doors and pull down attic stairs or ladders are described each of which is formed of an insulating material. The covers are structured to effectively seal a ceiling access opening. In some embodiments, a closure member constructed of insulating material is cooperatively and frictionally received within a frame formed of the same material to form an airtight seal therebetween.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to covers used to prevent loss of heat duringcold weather and loss of cool air during hot weather that is caused by aceiling trap door and/or pull down attic ladder or stairs in a building.

2. Description of the Prior Art

For all homes with an attic trap door and/or pull down attic ladder,there is typically only a thin plywood closure used to provideinsulation for the area of the trap door or pull down ladder (opening).This opening creates a gap in the insulation of the building. Theplywood door typically has an insulating R-Factor of 0.5 or less, whilethe rest of the attic has insulation of R-19 or greater. There have beena number of inventions to date that have addressed this problem with twomain approaches.

There are a number of one-piece covers. U.S. Pat. No. 4,299,059discloses a ceiling door that is insulated and to which an attic ladderis attached. U.S. Pat. No. 4,151,894 discloses a one-piece cover for anattic opening that fits over the attic door. It is double walled andable to contain a layer of insulation. U.S. Pat. No. 4,281,743 similarlyprovides a one-piece cover for an attic opening that fits over the atticdoor. This cover, however, is a shell, comprised of multiple pieces thatneed to be assembled in a tongue and groove design into which insulatingpanels are inserted. U.S. Pat. No. 5,475,955 discloses a two-piece shellthat is able to contain insulation. U.S. Pat. No. 4,832,153 is also aone-piece cover for an attic opening. This cover consists of detachablecomponents that can be stored or attached with assembly components toserve as an insulating cover. U.S. Pat. No. 4,928,441 discloses aninverted tub shaped cover that is hinged to an attic floor. U.S. Pat.No. 5,271,198 discloses a compartmentalized plastic or fiberboard shellwith a moisture barrier insert that can accommodate insulation. U.S.Pat. No. 5,628,151 discloses a one-piece shell with multiple pocketsthat can hold insulation.

There have also been other two-piece covers. U.S. Pat. No. 4,344,505discloses a stationary frame with a hinged door that opens to an uprightposition. The door and frame are made of insulated material and coveredwith wood furring for securing the hinges to the door and frame. Thedoor merely rests on the frame. U.S. Pat. No. 4,591,022 discloses aframe and door, but the door is in three pieces. In order to open thedoor, it collapses in an accordion manner to gain access to the attic.The frame consists of components that are attached and secured to theattic floor with hinges.

U.S. Pat. No. 4,312,423 discloses an all in one approach for a ladder,insulating cap and packaging container.

With each patent, there are some consistent elements. Each patentreferenced above is not in itself an insulating solution. Rather, it isa shell made of various materials into which one can insert insulation.Thereafter, each solution has distinguishing ways to affix the cover tothe attic and open the cover to access the attic. The shells requiresome assembly.

SUMMARY OF THE INVENTION

It is a principal object of this invention to provide an insulatingenclosure for both trap door and pull down attic door accesses toattics. Each insulation enclosure includes a door or closure memberwhich is elevated as a unit relative to an attic access opening to gainaccess to the attic and which is sized to seal the access opening whenin place. Each door or closure member is primarily constructed of a foaminsulation material having a thickness to create an insulation “R” valuewhich is equal to or greater than values set for attic insulations. Thematerial is preferably an expanded polystyrene material which is sealedand coated on its entire exterior surface with a plastic shell or layer,such as an elastomeric resin, which layer is coated with a fireretardant paint or sealant.

A first embodiment of the invention consists of two components. First, aframe that rests in the attic above a trap door or pull-down door, withor without a ladder, and second, a door or closure which rests on andwithin the frame in such a manner as to create a snug fitting. Thiscombined solution provides a high insulating device that is the same orgreater R-Factor as the insulation contained in the attic floor.

Both the door or closure and frame can be moveable so as to provide themaximum flexibility to access the attic and bring in and remove largeobjects or the frame can also be secured to the attic floor so as to beimmoveable. The moveable frame provides an added benefit for attic trapdoors and attic ladders that are situated below a low area of the attic.

Both the frame and closure are lightweight so that men, women and youthcan readily maneuver the devices.

Both the frame and closure are made principally of insulating materialsuch as expanded polystyrene with a plastic covering or coating toprotect them from wear as necessary and which is also coated with aretardant to provide fire resistance.

The closure may have handles on the bottom so that the closure can begrasped, lifted and moved for access to the attic. In preferredembodiments, the handles are mechanically secured to a separate rigidstrip of wood or dense plastic with the strip being formed to be securedto the closure members by being interfitted or keyed into assembledrelationship therewith.

The frame is of sufficient height so as to accommodate a pull downladder in its upright and folded position in the attic. The frame has alength and a width that either exceeds the opening in the attic floorthat is made for a trap door or pull down ladder or is the same size.

The frame may have handles on the sides so that the frame also can begrasped, lifted and moved for access to the attic. The handles arepreferably attached as described above with respect to the closuremember.

The bottom of the closure and top of the frame are cut in one of aplurality of ways to create a close fitting. A first way is such as tocreate an inlaid fitting. In this way, the bottom of the closure isparallel to the perimeter of the rest of the closure, but slightlynarrower than its framing, thus creating a lip. The top of the frame ismade so that there is a matching opening inside the perimeter of theframe in such dimension so that it can receive the closure and form onerectangular piece.

A second fitting is achieved by a beveled cut on both the bottom,outside edges of the closure and the top inside edges of the frame. Theclosure is beveled inwardly from the top and becomes narrowerthereafter. The frame is cut in the same way so as to accept the beveledcut of the closure and thereby fit and form one rectangular piece.

The bottom of the frame is also in two different designs. Particularlyfor those attics that have support trusses on the edge of or very closeto the opening in the attic that is narrower than the opening in thefloor. The outer edge of the frame is no wider or longer than theopening for the trap door or pull down ladder. This creates a lip in thebottom of the frame that rests on the opening in the attic floor for thetrap door or pull down ladder. This allows the frame to fit into theopening for the trap door or pull down ladder without interfering withthe attic support trusses.

The second design for the bottom of the frame is for attics with someamount of flooring around the trap door or pull down ladder. In thiscase, the frame is slightly wider and longer than the opening for thetrap door or pull down ladder and it rests on the attic flooring.

A second embodiment of the invention is for use in structures where noattic stairs are used with the attic trap door. In many of theseinstances, a wooden frame is provided including a peripheral lip onwhich the trap door is seated. In this embodiment, only the closuremember is used. The closure member includes a body portion of a size tosnugly fit within the frame defining the access opening to the attic. Aperipheral ledge or flange extends outwardly from the top of the body soas to support the body from the upper edges of the structural frame. Theclosure member is constructed of the same material and is sealed andfireproofed as previously described.

With the second embodiment, in some housing structures, a one-piececlosure member can not be inserted through the access opening.Therefore, the closure members may be formed of two components which aredesigned to interfit with one another after being inserted through theaccess opening and are retained in assembled relationship, such as bygluing.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross sectional illustrated view of a first embodiment ofthe invention showing the insulating cover mounted above a conventionalattic pull down ladder;

FIG. 2A is an exploded perspective view in partial cross section of amodification of the embodiment of FIG. 1;

FIG. 2B is a cross sectional assembly view of the modification of FIG.2A showing attic support trusses and with the pull down ladder raised;

FIG. 3 is an assembly view of the modified embodiment of FIG. 2A showinghandles applied to the frame;

FIG. 4 is a perspective bottom view of the closure member of FIG. 3showing handles applied to the closure;

FIG. 5 is a front perspective assembly view of another variation of thefirst embodiment of the invention;

FIG. 6 is a perspective assembly view of a preferred manner of securinghandles to the closure members and frames of the invention shown withthe closure member of FIG. 5 but being the same for all embodiments ofthe invention;

FIG. 7 is a cross-sectional view of a second embodiment of the inventionwherein the closure member is used without a separate insulation supportframe;

FIG. 8 is a perspective assembly view showing a variation of the secondembodiment wherein the closure member is formed from two components bykeying or interlocking the components relative to one another;

FIG. 9 is a partial cross-sectional view of an alternate variation ofthe second embodiment showing a different interlocking relationshipbetween the components of the closure member;

FIG. 10 is a view similar to FIG. 9 showing a further variation of aninterlocking joint between the components of the closure member;

FIG. 11 is a view similar to FIG. 9 showing a further variation of aninterlocking joint between the components of the closure member; and

FIG. 12 is a view similar to FIG. 9 of a further variation ofinterlocking joint between the components of the closure member.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Although the present invention will be described hereinafter withparticular reference to the accompanying drawings, it is to beunderstood at the outset that it is contemplated that the presentinvention may be varied in specific detail from that illustrated anddescribed herein while still achieving the desirable characteristics andfeatures of the present invention. Accordingly, the description thatfollows is intended to be understood as a broad enabling disclosuredirected to persons skilled in the applicable arts, and is not to beunderstood as being restrictive.

With specific reference to FIGS. 1-6 a first embodiment of the presentinvention is disclosed. In FIG. 1 an insulated cover 10 for an atticclosure is shown as being mounted so as to rest on an attic floor 11 insurrounding relationship with respect to an access opening 12 into anattic. As shown, the attic is normally closed by a trap door 14 whichmay, in some instances, be formed as a part of a fold down ladder orstairs 15. In some instances, no ladder is provided in which case thetrap door is mounted within a frame which is provided in the ceilingaround the access opening such that the trap door may be insertedupwardly through the access opening and then rest on the frame therebyclosing the access opening to the attic.

As previously discussed, conventional trap door and trap door fold downladder or stairs combinations are areas in which thermal losses occur inmost building structures as the thermal insulating properties of thetrap door is not nearly that of the insulation which is used in theattic space.

The insulated cover 10 includes an open frame 20 having elongatedgenerally parallel side walls 22 and generally parallel spaced end walls24. In the embodiment shown, the frame is generally rectangular orsquare in configuration and the height “H” of the walls of the frame issufficient that the upper edge of the frame extends above any ladder orstairs that may be positioned within the access opening. The frame ispreferably of a size to extend along the edge of the access opening asshown in FIG. 1 so as not to interfere with the access opening.

The frame 20 is designed such that it may simply rest on the floor ofthe attic space, however, in some instances, the frame may be secured tothe floor.

The insulation cover 10 also includes a removable closure member 26which is preferably formed of the same insulating material as the frame20. In the embodiment of FIG. 1, the closure member includes a centralbody portion 27 which depends below or extends outwardly relative to anupper portion 28 such that the upper portion defines a peripheral ledge29 for the closure member. The central body portion is specificallydesigned to be of a size to snugly and frictionally engage within acentral area 25 defined by the frame 20, as shown in FIG. 1, such thatthe ledge extends outwardly into general alignment with the outer edgesof the frame. This snug interfitting relationship between the closuremember and the frame forms a generally “L-shaped” seal which preventsair from passing between the closure and the frame when positioned asshown in FIG. 1, thereby providing maximum thermal efficiency when inuse.

Because of the manner in which the closure member snugly engages withinthe frame 20, in preferred embodiments, one or more handles 30 areprovided which extend from the lower surface 31 of the main body of theclosure member. In this manner, the handles may be engaged to force theclosure member into snugly fitted relationship with the frame when inuse. Also, as shown in FIG. 3, to facilitate maneuvering of the frame,handles 32 may be secured to one or more side walls thereof, as is shownin the drawing figures.

Both the frame and the closure member are preferably made of lightweightdense insulating board such as an expanded polystyrene material withR-Factor sufficient, when used in conjunction with one another, toprevent lost of cool air from a structure when the ambient weather iswarm and to prevent the loss of warm air from the structure when theambient weather is cool. Further, to provide for safety, ease ofassembly and durability, the frame is sealed by a plastic shell or layerwhich is coated with a fireproof material, as shown at 35 in FIG. 2A. Ina like manner, the closure member is also sealed and coated with thesame plastic shell and fireproof material, as shown at 36. The fireretardant coated layers are preferably an elastomeric resin. Thefireproof or retardant coating may be paints or sealants which meet firehazard classifications ASTM E-84 (NFPA 255) Class A. One such product isSherman Williams™ Flame Control No. 20-20, an intumscent material.

FIGS. 2A-4 show a variation of the embodiment of the invention shown inFIG. 1. In this variation, the closure member 26 is the same as thatdescribed with respect to the previous variation. However, in thisvariation, the frame 38 is designed to be partially seated within aframe 40 defining the access opening into the attic. In some fold downladder structures, the ladder is attached to a secondary frame 41mounted within the primary access opening, as shown in FIGS. 2A and 2B.Further, the wooden frame 40 may be suspended from vertical supporttrusses 40A secured to adjacent floor joists 41A. In these instances theframe must fit to the framed opening without interference with thetrusses. Thus, the frame of the invention may be formed with an innerdepending flange 42 which is of a size to frictionally seat within theframe 40 defining the access open such that the lower surfaces 43thereof abuts the secondary frame 41 of the pull down ladder. With thisstructure, the upper and outer portion of the frame also forms agenerally horizontal lip 44 which extends along the periphery thereofwhich seats and seals against the upper portion of the frame 40 definingthe access opening inside of the trusses 40A.

In the variation shown in FIGS. 2A-4 the materials and the manner inwhich the closure member seats with respect to the frame is the same asthat previously described.

With respect to FIG. 5, a further variation of the first embodiment ofthe invention is shown. In this variation, as opposed to having theclosure member and frame configured to form a generally L-shape sealarea between the components of the insulation cover, the frame 48 isformed having internally beveled surfaces 50 which extend inwardly fromupper edges 51 toward lower edges 52 thereof such that the inner sidewalls taper inwardly from the top to the bottom of the frame. A closuremember 53 includes opposite side walls 54 and opposite end walls 55 eachof which is beveled inwardly from the top 55 toward the bottom 56 of theclosure member. The configurations of the beveled surfaces are designedsuch that the closure member 53 seats and seals with the side wallsthereof against the tapered side walls of the frame. The material usedin this embodiment is the same as that as previously described.Although, not shown in FIG. 5, appropriate handles may also be providedon the frame and on the closure member to facilitate maneuvering of eachcomponent when necessary.

In this respect and with specific reference to FIG. 6, a preferredmanner of securing handles to the various embodiments of the inventionis shown. A closure member 53′ similar to that shown in FIG. 5, is shownas including a groove or channel 57 formed therein defined by undercutor beveled opposing edges 58. The channel is formed during molding.Handles 59 are secured by mechanical fasteners to a slide strip 60 ofwood or dense plastic which is mechanically able to retain the fastenerswithout fracturing. The side edges 61 of the strip are beveled tointerlock within the channel by sliding the strip as shown by the arrowsin the drawing figure. Glue or other adhesive is used to secure thestrip to the closure member. Securing the handles in this manner isimportant as the material from which the closure members and frames ofthe invention are constructed, is not suitable to securely mount handleswithout material failure.

With reference to FIG. 7, another embodiment of the invention isdisclosed. This embodiment is particularly suited for use with atticaccess openings which do not have folding ladders or stairs and whereinthe access openings 62 are defined by structural wooden frames 63 towhich finishing strips 64 are attached to define a peripheral ledge forsupporting an attic trap door 65. In this embodiment, only the closuremember 66 is used and no insulation frame is used, as is the case in theprevious embodiment.

As shown, the closure member 66 is constructed in the same manner as theclosure member described with respect to FIGS. 1-4 having a body portion67 of a size to fit snugly within the structural frame 63. A peripheralflange 68 extends from the body and is designed to provide a sealagainst the upper surface of the structural frame 63. Although notshown, handles may be provided, especially as described with respect tothe closure member of FIG. 6. The closure member is constructed of thesame insulating material described with respect to the previousembodiment and is sealed and coated with a fireproof coating aspreviously described.

In some instances, attic access openings are relative small orpositioned close to a roof line thereby limiting the ability to insertsingle piece closure members into position. The present embodimentincludes variations wherein the closure member is formed of twointerfitting components which may be adhesively secured to one anotherafter being inserted into an attic space above an attic trap door accessopening.

As shown in FIG. 8, a closure member 69 includes two components 70 and71, each having a body portion segment 72, 72′, respectively, and upperflange segment 73, 73′, respectively. Component 70 includes a channel 74having opposing beveled side walls 75 in which an elongated tongue orflange 76 of the opposing component is slidingly received. The shapes ofthe channel and tongue are such that the two components may beinterlocked by sliding relative to one another to thereby form a singleclosure member. Adhesive or glue is applied in the joint prior tofitting or the interfitting edges may be coated with adhesive stripswhich are applied during manufacturer and covered with appropriateremovable tape such that the user need not apply separate glue oradhesive during assembly.

The general configuration and the materials from which the assembledclosure member is formed are the same as that discussed with respect tothe previous embodiment. In the drawing figures, only a portion of oneside of each closure member is shown for purposes of showing theinterlocking relationship therebetween.

In FIG. 9 a variation is disclosed in which the closure member 78includes a first component 79 having a generally u-shaped channel 80 inwhich a protruding tongue 81 of an opposing component 82 may bereceived. The components may be secured as previously described tothereby form a single closure member.

In FIG. 10, the closure member 83 includes a first component 84 having apair of slots 85 and 86 which are generally u-shaped in section whichreceive protruding tongues or flanges 87 and 88 which extend from anopposing edge of frame component 89. Again, the components areadhesively secured as previously described.

In FIG. 11, another type of sealing relationship is disclosed betweenopposing edges of two components of a closure member 90. In thisvariation, the closure member includes a first component 91 including acentral v-shaped channel 92 defined by opposing beveled edges and outerbeveled edges 93 and 94. The beveled edges cooperate with elongatedtapered flanges 95, 96 and 97 defined along the opposing edge ofcomponent 98 such that when the members are seated with respect to oneanother, a very tight seal is created therebetween.

With specific reference to FIG. 12 a further variation of the presentembodiment is disclosed. In this embodiment, the closure member 99includes a first component 100 having an L-shaped cut-out or recessformed along each of the side and end walls, as shown at 101, which isof a size to cooperatively engage an L-shaped cut-out 103 formed in theopposing edge portion of component 104. The components are adhesivelyjoined after being inserted into an attic space as previously described.

The present invention is designed to be lightweight and yet formed ofinsulating material that will provide for maximum insulating value whenthe cover is placed into use. Because of the interfitting relationshipof the closure member with the inner surfaces of the support frame orwith a structural frame, a very tight seal is provided which furtherensures maximum insulating efficiency.

The foregoing description of the preferred embodiment of the inventionhas been presented to illustrate the principles of the invention and notto limit the invention to the particular embodiment illustrated. It isintended that the scope of the invention be defined by all of theembodiments encompassed within the following claims and theirequivalents.

1. An insulating cover assembly in combination with an existing atticaccess, the combination comprising: an existing attic access having asurrounding structure integral to a ceiling of a building and providingaccess to said building's attic, said existing attic access defining anexisting attic access opening therethrough and having an existing trapdoor for closing said existing attic access opening; an insulating coverplaced on said surrounding structure and including: a continuous framehaving spaced side walls and spaced end walls and which frame is formedof a free standing insulating material having an upper surface and alower surface, said frame defining a frame opening therethrough, saidframe opening being aligned with said existing attic access opening,said frame being of a size and configuration so as to enclose saidexisting attic access opening when said lower surface is supported onsaid surrounding structure; and a removable closure member formed of afree standing insulating material, said removable closure member notbeing bonded to any portion of said continuous frame and said removableclosure member including: a depending central portion, said dependingcentral portion being sized and shaped to fit within said frame openingdefined by said frame and fictionally and snugly engage each of saidside walls and said end walls of said frame inside said frame opening tocreate a first continuous seal with said frame when said removableclosure member is positioned on said frame in a covering relationshipwith respect to said frame opening; and an upper portion formingflanges, said flanges extending laterally outward relative to saiddepending central portion, said flanges being sized and shaped tofrictionally and snugly engage an upper surface of each of said sidewalls and end walls of said frame to create a second continuous sealwith said frame when said removable closure member is positioned on saidframe in covering relationship with respect to said opening defined bysaid frame; wherein said closure member is not hinged to and detachesfrom said frame when said first continuous seal and said secondcontinuous seal are broken by a force applied to said removable closuremember through said frame opening, leaving said frame enclosing saidexisting attic access opening; and wherein said first seal and saidsecond seal are generally orthogonal to each other when said removableclosure member is positioned on said frame in covering relationship withrespect to said opening defined by said frame.
 2. The combination ofclaim 1 including at least one handle extending from a lower surface ofsaid removable closure member so as to be accessible within said frameopening when said removable closure member is positioned on said framein covering relationship with respect to said frame opening.
 3. Thecombination of claim 1 in which said removable closure member includesat least first and second components each having opposing edges whichare configured to cooperatively engage one another to create a sealtherebetween, and means for adhesively securing said opposing edges soas to form a unified removable closure member.
 4. The combination ofclaim 1 in which said insulating material of said removable closuremember and said frame is an expanded polymeric material.
 5. Thecombination of claim 1 wherein said trap door comprises a hatch.
 6. Thecombination of claim 1 wherein said trap door is attached to a fold downattic access ladder.
 7. The combination of claim 1 wherein saidremovable closure member comprises two pieces, the two pieces having aseal between them when positioned on said frame in covering relationshipwith respect to said frame opening.
 8. The combination of claim 7wherein said two pieces are adhered together.
 9. An insulating coverassembly in combination with an existing attic access, the combinationcomprising: an existing attic access defining an existing attic accessopening therethrough and having an existing trap door for closing saidopening; a continuous frame having spaced side walls and spaced endwalls and which frame is formed of a free standing insulating material,said frame defining a frame opening therethrough for alignment with saidexisting attic access opening, said frame being of a size andconfiguration so as to surround said existing attic access opening, saidframe also including a generally continuous depending portion extendingdownward from each of said side and end walls, said generally continuousdepending portions being configured so as to extend into said existingattic access opening and to frictionally seal to said existing atticaccess opening; and a removable closure member formed of a free standinginsulating material, said removable closure member not being bonded toany portion of said continuous frame, and said removable closure memberincluding: a depending central portion, said depending central portionbeing sized and shaped to fit within said opening defined by said frameand frictionally and snugly engage said side walls and end walls of saidframe inside said opening to create a first continuous seal with saidframe when said removable closure member is positioned on said frame incovering relationship with respect to said opening defined by saidframe; and an upper portion forming flanges, said flanges extendinglaterally outward relative to said depending central portion, saidflanges being sized and shaped to frictionally and snugly engage anupper surface of said frame to create a second continuous seal with saidframe when said removable closure member is positioned on said frame incovering relationship with respect to said opening defined by saidframe; wherein said closure member is not hinged to and detaches fromsaid frame when said first continuous seal and said second continuousseal are broken by a force applied to said removable closure memberthrough said frame opening; and wherein said first seal and said secondseal are generally orthogonal to each other when said removable closuremember is positioned on said frame in covering relationship with respectto said opening defined by said frame.
 10. The combination of claim 9including at least one handle mounted to extend from a lower surface ofsaid depending central portion of said removable closure member so as tobe accessible within said frame opening when said removable closuremember is positioned on said frame in covering relationship with respectto said frame opening.
 11. The combination of claim 1 wherein saidremovable closure member and said frame are coated with a fire retardantmaterial.